GE – Ericsson - M/A-COM – Tyco
Transcript of GE – Ericsson - M/A-COM – Tyco
GE – Ericsson - M/A-COM – Tyco Orion 900 MHz Orion 900 MHz Orion 900 MHz Orion 900 MHz Amateur Radio 902 Amateur Radio 902 Amateur Radio 902 Amateur Radio 902----928 Hardware Modifications928 Hardware Modifications928 Hardware Modifications928 Hardware Modifications Released 2Released 2Released 2Released 2----24242424----09, 09, 09, 09, updated updated updated updated 3333----4444----09 09 09 09
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Douglas Bade KD8BDouglas Bade KD8BDouglas Bade KD8BDouglas Bade KD8B
Josh Heide K6ZRXJosh Heide K6ZRXJosh Heide K6ZRXJosh Heide K6ZRX BackgroundBackgroundBackgroundBackground The Orion Mobile is one of several radio members in
the EDACS product group. The Programming tools used on
Orion’s in the early day were DOS based tools. There were 2
versions, EDACS3 and a CONVentional equivalent. The current
software used for these radios is called Programmer and
Programmer CNV. These newer windows based tools are
licensed currently by Tyco and are beyond the scope of this
document. If you have a legitimate version of these tools
you may have other software solutions to get to amateur but
these or similar hardware mods will still be required. We
will confine our discussions in the software realm to the
DOS based tools which are for the most part available and
not restricted or protected per-se by the current owners of
Tyco.
(Editors Note: Information regarding Using EDACS3 or CNV DOS based
software to move these radios into amateur frequencies is published in
some places on the internet. The methods of doing this are not
publically approved, authorized or supported by Tyco/ M/A-Com TAC
Support in Lynchburg... DO NOT CALL THEM for assistance!!!! I REPEAT DO
NOT CALL THEM TO ASK HOW TO MOVE RADIOS OUT OF BAND. You will not get
an answer that you want to hear… The Factory in no way publically or
officially supports or assists Out-of-Band modifications outside of
commercial activities for commercial customers. Period!!!) The older
DOS based software is available in the wild and in general is not
scrutinized nor is it supported by the Factory... Special Configuration
files can be used with these DOS based software tools to program Out-
Of-Band amateur frequencies.
Assuming you have been able to program 902-927
frequencies into your 900 Orion, you have probably noticed
that simplex works and RPT (902) TX gives a synthesizer
unlock. This is absolutely correct and applies to all
EDACS3 radios I have tried except the MRK 900 which works
fine, as it only has 1 segment.
The problem is simple but a little difficult to find a
solution for. What occurs is a firmware quirk which
probably came from the software engineer never considering
use on anything besides 896-902 and 935-941 which are the
commercial band segments (He or She must not have been a
ham). SO … he or she, as the case may be, took some
shortcuts in decision making steps for the IC702 CPU.
There are 2 VCO band segments in the hardware for
selecting the low range or high range in Transmit mode. ALL
EDACS3 radios in 900 make one of 2 decisions that being
either (1) anything below 935 is the low VCO or (2)
anything above 902 is the high VCO.
This varies by model but the results is the same, on
either 927 TX or 902 TX one will work or one will not
because our band 902-928 segment is in between these
limits. In the specific case of the Orion the decision made
is anything above 902.0000 is sent to the high VCO so the
radio tries to use this high VCO segment to operate and
consequently unlock occurs.
A hardware solution is in order. The mod discussed in
this document will provide a manual over-ride switch
function to correct this hardware condition. In software a
button on the front of the radio will be mapped to do this
RPT and T/A switching as well as enabling or disabling
TR716 “OUT1” to switch the segment. Option 1 and Option 2
use identical software setup except the active condition of
Out1 is HIGH or LOW based on which version of the
modification. The choice will be described later but are
HIGH for Mod option 1 (Josh’s) and LOW for option 2
(Doug’s). Josh worked out the Macro function programming
for the button. I give him all the credit on that as I
never knew it could even do that ☺ …
Even I can learn a thing or 2 about Orion’s!!! And the
setup is pretty cool. It is elegantly simple but highly
effective.
The actual schematic designator of the VCO segment
selectors on the 900 Orion transmit involved is the “SYNTH
BAND 1” circuit. This lead needs to toggle HIGH when the
low VCO segment is needed and is held LOW when the
TALKAROUND mode or high segment is needed. This signal
comes from the Microprocessor (IC702) which is on the
System Control/Logic Board. The signal starts at IC702 and
passes through a choke SMT assy (CX702 in a ceramic IC
package) and then through pin 25 of P501 to the
Synthesizer/Receiver/Exciter board. Basically the lead is
never switched to high when we operate out of band in 902-
928 because of the above described firmware logic. We need
to fix that.
The OPTIONS
We propose 2 different modifications depending on the
skill level and desire of the builder and his or her
confidence level. No egos allowed here… check it at the
door. Mistakes can kill the board. Do not attempt the
second option unless you are ready to cut a tiny foil and
have a soldering pencil tip in 1mm region, as well as a
magnifier and patience. The cut requires cutting 1 foil
with a lot less than 1mm of clearance to everything around
it. A precision X-acto knife, a magnifier and a steady hand
are a must. You have been warned!
Josh proposes a single wire installation with no cuts
or major surgery. It does also require drilling one little
hole through the chassis frame. We will refer to his as
Option 1.
I (Doug) propose a 1 wire, 1 cut, and 1 resistor mod
if the operation of the mod proposed by Josh does not suit
your liking. We will refer to mine as Option 2.
The decision is an operational one, now on to the
decision discussion.
The Reasoning for which Option Solution
Based on a firmware glitch, or feature, depending on
your perspective, the OUT1 transistor device, TR716, always
powers up in the OFF mode (it is an open collector NPN
device and powers up in the open floating condition) upon
power “ON” or reset of the radio. The relevance of this
dictates which Option you will choose to follow.
If you use Josh’s mod, the transistor (TR716) will
power up open collector (floating) and activate the T/A or
SIMPLEX segment select mode until the “Talkaround” button
is toggled (discussed later) which causes a synthesizer
unlock condition in RPT mode if you try to transmit on RPT
before the Talkaround/RPT button is cycled. The display
will indicate RPT mode but the transistor will be latched
in TALKAROUND and activate the talkaround VCO segment until
cycling the T/A button twice. If you try to TX it will give
an unlock condition on an RPT freq and in the wrong state.
This may or may not be reason to contemplate my more
complex mod (option 2) which inverts the situation making
the radio always power up with the transistor in the open
state but instead because we invert everything, it will be
in RPT mode and will let the radio TX work immediately
without cycling buttons as long as the radio was in RPT
mode when power was shut off.
You NEED to decide if this issue is an issue or not.
The main difference is that if you are using the radio in
RPT mode (which is after all why we are doing this mod)
most or all the time, that power on and power off is a 1
switch function my way (option 2), and you additionally
need to toggle the “Talkaround” button twice before using
on RPT using Josh’s simpler non invasive mod (option 1).
This document includes both. The difference is where
we tie to the Band Select lead and which logic level is
default. The logic line inverts before it gets to the Band
Select of the VCO so we can attack it at either side of the
inverter. The connection points are on 2 different boards
depending on option 1 or option 2. In either case the OUT 1
transistor TR716 is still the other end of the wire.
Modification instructions start here:
1. You need to address the programming of amateur
frequencies first and verify operation on simplex before we
get started… This is important because after you start
making modifications, if something goes wrong it will be
hard to tell why if we did not check the radio out first.
Do not skip this step!!!!
2. When you have the radio programmed on the ham bands,
and working on 927 MHz TX and RX simplex, you will see that
the radio unlocks the VCO, indicating "VCO Unlock", if you
attempt to TX on 902 or basically anything below 925 or so…
Next you need to, and are ready to, modify the
hardware of the radio.
Use ESD safe work practices so you don't fry the radio
you are trying so hard to make work.
Other than basic hand and soldering tools, you will
need one item to complete this version of the mod....
A piece of small gage wire!
Teflon insulated wire is best, for abrasion
resistance, but use what you have. It will have to pass
through a hole in the frame of the radio so make sure it
can handle a little chaffing...and is small enough. You
will need to drill accordingly.
1. Remove the PA and set it aside to get it out of the
way.
2. Remove the top and bottom covers and internal shields.
3. If it is a dash mount radio, remove the control panel
from the front.
4. Disconnect and remove the LOGIC circuit board and set
it aside for option 1 or prep it for option 2.
Here we deviate for Option 1 and 2, first will be the
modification instructions for Option 1
5.1 Remove the VCO circuit board and set it aside.
6.1 On the Logic side of the chassis you will see a raised
boss that is the heat sink for the 7805 regulator chip. Set
the chassis in front of you with the boss to the right. On
the side of the boss facing you (towards the front of the
radio) drill a 1/16” hole right along the boss on the front
side about 1/8-3/16” of an inch from the end of the boss.
This is where the VCO control wire you add will pass
through the chassis.
7.1 Place the VCO board front and center on your bench,
component side down with the connector to the Logic board
closest to you. The VCO adjusting caps should be towards
the bench on your right hand side. Locate the surface mount
resistor and capacitor near two plated through holes in the
board. These will be towards the right edge with nothing
between them and the far side of the board. They will be
near one of the holed for VCO board shield mounting. The
cap is marked 102 and the resistor marked 472. They share a
common connection. This line is the “Synth Band 1” line
from the micro. The resistor is the current limiter for the
transistor this line drives. It is high for talk around VCO
and low for repeater input VCO. We will be pulling this
line low to make the radio lock at 902-903MHz. We can do
this without damage to the micro since this resistor is in
the circuit. Carefully solder a length of small, insulated
wire to the right hand side of the resistor (the trace
leading to the cap and the plated through hole).
8.1 Run the wire through the hole you drilled in the
chassis and reinstall the VCO board. Do not let the wire
loop up or collect under the VCO board. Gently pull it as
you place the board.
9.1 On the Logic side of the chassis, run the wire around
the 7805's heat sink boss and out the cutout in the chassis
for the PA connections. Reinstall the Logic board, keeping
this wire out of trouble under the circuit board.
10.1 With the Logic board side up, and the front of the
chassis towards you, locate TR716 on the Logic board, near
the back of the radio. There are two identical transistors
in front/back of each the other. TR716 is the one farthest
to the back. They have 3 leads on the right side, and one
larger one on the left. Bring your wire up and around the
back of the board and solder it to the center pin on the
right side. This is "Output 1" that you will use to control
the VCO. (Editors note: the large lead on the left is
internally connected to the center pin on the right, which
is the collector of the "Output 1" transistor.)
11.1 Locate J703 and consider cutting the traces that lead
to pins 3 and 4. "Output 1" appears on pin 22 of the 37 pin
connector. By cutting the traces, you ensure that nothing
will be connected and damage the modified circuit.
This is NOT mandatory, but suggested, as the voltages you
might apply accidentally on this pin externally could blow
things up in the future… Cutting the pin loose will prevent
the possibility.
12.1 Reinstall the shields and covers. Reinstall the PA
deck.
Next are changes to instructions to modify using the
alternate Option 2
5.2
You will need a 1.2k or so 1/8 or 1/4 watt resistor. A
very sharp X-acto knife. A magnifier lens of some form, a
steady hand, and a piece of small gauge Teflon wire that
will have to pass under the board. I use Teflon wire wrap
wire. Lastly a fine tip soldering pencil… 1mm or so.
6.2
The foil cut is on the MCU Logic Board in between the
CX702 device and P501. The foil is connected to P501 pin 25
and the corner pin of CX702 on the bottom solder side of
the logic board. If it looks too tight to for you to work…
STOP! Go back to modification Option 1. This is the hardest
part so if you can do it the rest is down hill. Assuming
you cut this and only this, you have just disconnected the
CPU from the band select lead.
The foil cut and solder connection at P501 pin 25
7.2
Next you will need to solder the teeny tiny wire wrap
wire to P501 pin 25 on the bottom side of the logic board.
Make sure not to connect to the CX702 side… it is close
space but just be careful. Carefully route the wire against
the bottom side of the logic board so it will pass next to
CX702 in the shield cutouts of the Orion chassis frame
which sits directly under the area we are working when you
re-assemble the unit. Route it back to where the Audio PA
hybrid mounts and pass it up to the top side of the board
in the corner of the PCB cutout for the audio hybrid. Be
aware of the shield boss’s which the board sits on and make
sure you do not put the wire in harms way. There is plenty
of space assuming using something small like 30 gauge.
Wire routing on bottom of Logic board avoiding pinch
points where ground boss’s will touch the board.
8.2
Set the board upright with the wire routed how it will
be in the final re-assembly. And drape it over the top for
now. We should now be looking at the top component side of
the board. We now will solder the 1.2k resistor flying lead
style from the collector of TR716 to the anode of diode
CD601. See the pictures and the LBI diagrams for the Logic
Board to sort this out.
Routing Wire up through the open space of the cutout
around the Audio Amp IC.
9.2
Lastly solder the wire from P501-25 to the end of the
1.2k resistor which connects to the Collector of TR716.
Wire connection topside of board to resistor
connection on TR716 side. The resistor is soldered to
collector tab on TR716 and cathode of CD601R which is
switched 9v.
Another view of wire connection to resistor top side
10.2
Reinstall Logic Board carefully aware to not pinch the
wire under the board while aligning for reassembly.
Reinstall the Power amplifier connecting the wiring as you
go and reassemble the front panel if present and you took
it out ( if it was I am sure you did ☺ )Make sure the wire
passes freely from bottom to top in the corner of the
cutout by the Audio Amp IC, staying clear not to pinch it.
****** This completes the hardware modification. ******
RADIO PROGRAMMING:
(No, not out of band. You already did that on your
own)
This is to enable the hardware button functionality
that we just wired together…
Conceptually, we are using the Output 1 driver
transistor to manage the Band Select lead when we toggle
between RPT TX on 902/903 and T/A TX when we are on Simplex
of the high side. These steps will set that up.
1. Under “Control Unit Keypads” select the control unit
your radio has an assign one button to “MAC1” (macro 1).
You will use a macro to select “Talkaround” and toggle the
VCO.
2. Under “Macro Keys” select “macro 1” and “press”. In
the box next to the number one select “Talk” and “Press &
Release”. This selects the talk around mode. In the box
next to the number two select “AUX1” and “Press & Release”.
This will toggle the output line we use to control the VCO.
3.1 For Option 1 use THIS setting.
Under “External IO” in the area that relates to AUX 1
select “Follow WHC Icon”, "Aux 1 output = 1", "Aux 1 active
= HIGH", and finally check the "aux 1 repeat" box.
3.2 For Option 2 use THIS Setting
Under “External IO” in the area that relates to AUX 1
select “Follow WHC Icon”, "Aux 1 output = 1", "Aux 1 active
= LOW", and finally check the "aux 1 repeat" box.
4. Save and Program the radio with this information.
This completes the radio programming for the VCO
control.
RADIO OPERATION:
When you press the key you assigned to “macro 1” you
will hear two beeps. The first one is the radio going into
“Talkaround”; the second is the output changing state.
Press it again to go back to repeater mode and ground the
VCO control line we added. This function toggles on and off
with each press of the button and latches until reset.
See how easy. Not bad for a couple hours of work.
73 de K6ZRX and/or KD8B